1993 DODGE TRUCK fuel type

•

5.9L
(DIESEL)
ENGINE
9 -
107
5.9L
(DIESEL)
ENGINE
SERVICE
PROCEDURES

INDEX

page

Camshaft
127

Crankshaft
138

Cylinder
Block
129

Cylinder
Head
113

Engine
Assembly
. 109

Engine
Front
Mounts
(Insulators
/
Brackets)
... 107

Engine
Rear Support
108

Gear
Housing
/
Cover
122

General
Information
107

Oil Cooler Element
/
Gasket
. 149
Oil
Filter
148
page

Oil
Filter
Bypass
Valve
. 148

Oil Pan
/
Suction Tube
146

Oil Pressure Regulator Valve
/
Spring
148

Oil Pump
146
Piston
/
Connecting
Rod
Assembly
134

Rocker
Levers
/
Push
Rods
112

Specifications—5.9L Diesel Engines
151

Tappet
125

Timing
Pin
123

Valve Clearance
Adjustment
...............
121

Valves
and
Valve Springs
116

GENERAL INFORMATION The
5.9
Liter
(359 CID)
six-cylinder diesel engine
is
an
In-line valve-in head type
(Fig. 1).

Fig.
1
Diesel
Engine
Description
This engine
is
designed
for No.2
Diesel Fuel. Only
use
No.l
Diesel Fuel where extended arctic condi­
tions exist (below -23°C
or -10°F).

Engine lubrication system consists
of a
gerotor
type
oil
pump
and a
full flow
oil
filter with
a
bypass valve.
The cylinders
are
numbered from front
to
rear;
1,

2,
3, 4, 5 and 6. The
firing order
is
1-5-3-6-2-4
(Fig.

2).
J898D-10
Fig.
2
Firing Order
The engine data plate
is
located
on the
driver side
of
the
engine forward
of the
fuel injection pump.
ENGINE FRONT MOUNTS (INSULATORS
/

BRACKETS)
REMOVAL (1) Raise hood
and
position
fan to
assure clearance
for radiator
top
tank
and
hose.
(2) Raise vehicle
on a
hoist. Support
the
engine.
(3) Remove
the
through-bolts
and
nuts from
the

bracket
(Fig. 3).

(4) Remove
the
nuts from insulator studs
(Fig. 3).
(5) Raise engine with
a
lifting fixture only
far

enough
to
remove
the
insulators
and
brackets. Mark
the locating
pin
position.
(6) Remove
the
engine mounting brackets from
the

engine block.
Engine Type
In-line
6
(Diesel-Turbo)
Bore and Stroke 102.0 x 120.0 mm
(4.02x4.72 in.)
Displacement 5.9L (359 cu.
in.)

Compression Ratio 17.5:1
Torque 542 N-m (400 ft. lbs.)

@
1,750 rpm
Firing Order
1-5-3-6-2-4

Lubrication Pressure Feed - Full Flow
Filtration w/Bypass Filter
Engine Oil Capacity
11.4L
(12.0 Qts) w/Filter
Cooling System Liquid Cooled
-
Forced
Circulation
Cooling Capacity
Manual Trans 15.2L (16.0 Qts)
Automatic Trans 16.2L (17.0 Qts)
Recovery Bottle 0.95L(1.0Qts)
Cylinder Block.... Cast Iron
Crankshaft Induction Hardened
Forged Steel
Cylinder Head Cast Iron
Combustion Chambers High Swirl Bowl
Camshaft.... Chilled Cast Iron
Pistons Cast Aluminum
Connecting Rods Forged Steel
J9209-48

9
- 148 5.9L
(DIESEL) ENGINE

• Make sure the idler gear pin is installed in the lo­
cating bore in the cylinder block. (2) Install the pump. Tighten the oil pump mount­
ing bolts in two steps and in the sequence shown (Fig. 2).
• Step
1—Tighten
to 5 N«m (44 in. lbs.) torque.
• Step 2-Tighten to 24 N*m (18 ft. lbs.) torque. (3) The back plate on the pump seats against the
bottom of the bore in the cylinder block. When the
pump is correctly installed, the flange on the pump will not touch the cylinder block.
(4) Measure the idler gear to pump drive gear
backlash and the idler gear to crankshaft gear back­ lash (Fig. 8). The backlash should be 0.080-0.330 mm (0.003-0.013 inch). If the backlash is out of limits, re­
place the oil pump drive gear and the idler gear.
(5) If the adjoining gear moves when you measure
the backlash, the reading will be incorrect.

Fig.
8
idler
Gear to
Pump
Drive Gear and Crankshaft Gear
Backlash

OIL FILTER
When replacing the oil filter, Chrysler Corporation
recommends use of the replacement filter specified in
your Operator's Manual.

CAUTION:
The
internal filtering medium
of
some
fil­

ters
has
been known
to
disintegrate. Debris from
failed filters
may
plug
the
piston
oil
cooling noz­

zles,
resulting
in
scuffed pistons
and
eventual
en­

gine
failure.
REMOVAL

WARNING:
HOT OIL CAN
CAUSE PERSONAL
IN­

JURY.

(1) Operate the engine until the water tempera­
ture reaches 60°C (140°F). Shut the engine off.
(2) Use a container that can hold at least 14 liters
(15 quarts) to hold the used oil. Remove the oil drain
plug and drain the used engine oil into the container.
(3) Always check the condition of the used oil. This
can give you an indication of some engine problems
that might exist. • Thin, black oil indicates fuel dilution.
• Milky discoloration indicates coolant dilution.
(4) Clean the area around the lubricating oil filter
head. Remove the filter using a 90-95 mm filter
wrench.
(5) Clean the gasket surface of the filter head. The
filter canister O-Ring seal can stick on the filter
head. Make sure it is removed.
INSTALLATION (1) Fill the oil filter element with clean oil before
installation. Use the same type oil that will be used
in the engine.
(2) Apply a light film of lubricating oil to the seal­
ing surface before installing the filter.

CAUTION:
Mechanical over-tightening
may
distort
the threads
or
damage
the filter
element seal.

(3) Install the filter as specified by the filter man­
ufacturer. (4) Clean the drain plug and the sealing surface of
the pan. Check the condition of the threads and seal­ ing surface on the oil pan and drain plug.
(5) Install the drain plug using a new sealing washer.
Tighten the plug to 80 N-m (60 ft. lbs.) torque.
(6) Use only High-Quality Multi-Viscosity lubricat­
ing oil in the Cummins Turbo Diesel engine. Choose
the correct oil for the operating conditions outlined in Group 0, Lubrication and Maintenance.
(7) Fill the enginfe with the correct grade of new

oil.
The engine capacity is i0.4 liters (11 quarts) in
the crankcase and 0.95 liters (1 quart) in the lubri­ cating oil filter. (8) Start the engine and operate it at idle for several
minutes. Check for leaks at the filter and drain plug.
(9) Stop the engine. Wait approximately 5 minutes
to let the oil in the upper parts of the engine to drain
back to the oil pan. Check the oil level again. Add oil as necessary to bring the level to the "H" (High)
mark on the dipstick.

OIL FILTER
BYPASS
VALWE
REMOVAL
(1) Remove the oil cooler cover (Fig. 9). (2) Remove the valve from the cooler cover (Fig. 9).
INSTALLATION (1) Drive the new valve in until it bottoms against
the step in the bypass valve bore (Fig. 10).
(2) Install the oil cooler cover.

OIL PRESSURE REGULATOR VALVE
/
SPRING
When oil pressure from the oil pump exceeds 448
kPa (65 psi), the regulator valve opens to allow oil to
drain back into the pan.

EXHAUST SYSTEM
AND
INTAKE MANIFOLD
11-15

FLANGE GASKET

o

o
CYLINDER

HEAD GASKET
J9209-101

Fig. 12 Intake Manifold Flange Gasket Alignment

®— INTAKE

MANIFOLD
FRONT OF
ENGINE
J9209-59

Fig. 13 Intake Manifold Bolt Tightening Sequence—3.9L Engines
V-8 ENGINE—(Fig* 14)
• Step
1—Tighten
bolts 1 through 4, in sequence, to 8 Nun (72 in. lbs.) torque. Tighten in alternating
steps 1.4 Nun (12 in. lbs.) torque at a time.
FRONT
OF ENGINE
J9209-60

Fig. 14 Intake Manifold Bolt Tightening Sequence—5.2L Engines
• Step 2—Tighten bolts 5 through 12, in sequence,
to 8 Nun (72 in. lbs.) torque. • Step 3—Check that all bolts are tighten to 8 Nun (72 in. lbs.) torque.
• Step 4—Tighten all bolts, in sequence, to 16 Nun (12 ft. lbs.) torque.
• Step 5—Check that all bolts are tighten to 16 Nun (12 ft. lbs.) torque.
(9) Install closed crankcase ventilation and evapo­
ration control systems. (10) Connect the coil wires.
(11) Connect the heat indicator sending unit wire.
(12) Connect the heater hoses and bypass hose.
(13) Install distributor cap and wires.
(14) Hook up the return spring.
(15) Connect the accelerator linkage and if so
equipped, the speed control and transmission kick-
down cables. (16) Install the fuel lines,
(17) Install the generator and drive belt. Tighten
generator mounting bolt to 41 Nun (30 ft. lbs.)
torque. Tighten the adjusting strap bolt to 23 Nun (200 in. lbs.) torque. Refer to Group 7, Cooling Sys­
tem for the proper adjusting of belt tension. (18) Install the air cleaner. (19) Fill cooling system (refer to Group 7, Cooling
System for the proper procedure). (20) Connect the negative cable to the battery.

ENGINE EXHAUST MANIFOLD
Engine exhaust manifolds are LOG type with port­
ing for air injection into the LOG.
REMOVAL (1) Disconnect the negative cable from the battery.
(2) Raise and support the vehicle.
(3) Remove the bolts and nuts attaching the ex­
haust pipe to the engine exhaust manifold. (4) Lower the vehicle. (5) Remove the exhaust heat shields.

11
- 22
EXHAUST
SYSTEM
AND
INTAKE MANIFOLD

•

DIFFUSER
TURBINE
HOUSING
O-RING BEARING
HOUSING
LOCKPLATE
J9111-9

Fig.
17 Diffuser and Lockplate
OIL
SLINGER

MO
Fig.
18 Diffuser,
O-Ring
and Oil
Slinger

THRUST
COLLAR
OIL
BAFFLE

J9111-11

Fig.
19 Oil
Baffle,
Thrust Bearing and Collar
(18) Remove the turbine shaft and heat shield
(Fig. 21).
(19) Inspect the turbine blades and the shaft for
excessive wear.
LOCK
PLATE

J9111-12
Fig.
20 Turbine
Housing Lock
Plates and
Clamp
Plates

TURBINE WHEEL SHAFT
PISTON RING TYPE SEAL

J9111-13
HEAT
SHIELD Fig.
21 Turbine
Wheel
Shaft and Heat
Shield

(20) Remove and discard the piston ring type seal
(Fig. 21).

CAUTION:
The
wheel
and
shaft assembly
is
bal­
anced
as a
unit.
If the
turbine blades
or
shaft
are

damaged,
the
complete assembly must
be
replaced.

(21) Remove and discard the outer retainer rings
(Fig. 22). (22) Remove and discard the turbocharger shaft
bearings (Fig. 22). (23) Remove and discard the inner snap rings (Fig.

22).
CLEANING
Use a stiff bristle nylon brush and solvent to clean
all parts. Do not use a wire brush on the compressor
wheel. Do not bead blast the parts. Remove the carbon build up from the housing with
a scraper and a 240 grit emery cloth.
Polish the bearing surfaces with crocus and kero­
sene or diesel fuel. After rinsing in clean solvent, use compressed air
to dry the parts.

INSPECTION
In addition to the inspection specified during disas­
sembly, inspect all parts after cleaning.

•

FUEL
SYSTEM
14 - 1

FUEL
SYSTEM

page

ACCELERATOR
PEDAL
AND THROTTLE
CABLE
................ 25

DIESEL
FUEL
INJECTION-COMPONENT
DESCRIPTION/SYSTEM
OPERATION
76

DIESEL
FUEL
INJECTION-GENERAL

DIAGNOSIS
88

DIESEL
FUEL
INJECTION-SERVICE

PROCEDURES
....................... 106

FUEL
DELIVERY
SYSTEM-EXCEPT
DIESEL
.. 3

FUEL
DELIVERY-DIESEL
ENGINE
15

FUEL
TANKS
.... 20
page

GENERAL
INFORMATION 1

MULTI-PORT
FUEL
INJECTION (MPI)-
COMPONENT
DESCRIPTION/SYSTEM

OPERATION-EXCEPT
DIESEL
29

MULTI-PORT
FUEL
INJECTION (MPI)-
COMPONENT
REMOVAL/INSTALLATION-

EXCEPT
DIESEL
64

MULTI-PORT
FUEL
INJECTION (MPI)-
GENERAL
DIAGNOSIS-EXCEPT
DIESEL
...43

SERVICE
ADJUSTMENTS-DIESEL
122

SPECIFICATIONS
123

GENERAL INFORMATION

Throughout this group, references are made to par­
ticular vehicle models by alphabetical designation or
by the particular vehicle nameplate. A chart showing a breakdown of the alphabetical designations is in­
cluded in the Introduction section at the beginning of
this manual.
The 5.9L (V-8) gas powered engine will be referred
to in this group as either the: LDC (Light Duty Cy­ cle) or HDC (Heavy Duty Cycle) engine. The HDC engine can be easily identified by the use of an en­
gine mounted air injection pump. The 3.9L/5.2L/5.9L
LDC engine will not use an air injection pump.
This Fuel System group will cover all fuel system
components for the 3.9L (V-6), 5.2L (V-8), 5.9L LDC
(V-8),
5.9L HDC (V-8) and 5.9L (in-line six cylinder)
diesel engines.
The Fuel System consists of: the fuel tank, an
electric (fuel tank mounted) fuel pump and fuel fil­
ter. It also consists of fuel tubes/lines/hoses, vacuum

hoses,
throttle body and fuel injector(s).
The Fuel Delivery System consists of: the electric
fuel pump, fuel filter, fuel tubes/lines/hoses, fuel rail,
fuel injectors and fuel pressure regulator.
A Fuel Return System is used on all vehicles (all
engines) except the 5.9L (V-8) gas powered engine. On this engine, a returnless type fuel system is
used. The fuel return system consists of fuel tubes/
lines and hoses that route fuel back to the fuel tank.
The Fuel Tank Assembly consists of: the fuel
tank, filler tube, fuel gauge sending unit/electric fuel
pump module, a pressure relief/rollover valve and a
pressure-vacuum filler cap. Also to be considered part of the fuel system is the
Evaporation Control System. This is designed to
reduce the emission of fuel vapors into the atmo­ sphere. The description and function of the Evapora­
tive Control System is found in Group 25, Emission Control Systems.

FUEL
USAGE
STATEMENT-GAS
ENGINES
Your vehicle was designed to meet all emission
regulations and provide excellent fuel economy using
high quality unleaded gasoline. Only use unleaded gasolines having a minimum posted octane of 87. If your vehicle develops occasional light spark
knock (ping) at low engine speeds, this is not harm­

ful.
However, continued heavy knock at high speeds can cause damage and should be re­
ported to your dealer immediately. Engine dam­ age as a result of heavy knock operation may not be
covered by the new vehicle warranty. In addition to using unleaded gasoline with the
proper octane rating, those that contain deter­

gents,
corrosion and stability additives are rec­
ommended. Using gasolines that have these additives will help improve fuel economy, reduce
emissions and maintain vehicle performance. Gener­ ally, premium unleaded gasolines contain more addi­
tive than regular unleaded gasolines. Poor quality gasoline can cause problems such as
hard starting, stalling and stumble. If you experience
these problems, use another brand of gasoline before considering service for the vehicle.

14
- 2
FUEL SYSTEM

•
GASOLINE/OXYGENATE
BLENDS

Some fuel suppliers blend unleaded gasoline with
materials that contain oxygen such as alcohol, MTBE and ETBE. The type and amount of oxygenate used
in the blend is important. The following are gener­
ally used in gasoline blends:

ETHANOL
Ethanol (Ethyl or Grain Alcohol) properly blended,
is used as a mixture of 10 percent ethanol and 90
percent gasoline. Gasoline with ethanol may be
used in your vehicle.

METHANOL

CAUTION:
DO NOT USE
GASOLINES CONTAINING
METHANOL.
Use of methanol/gasoline blends may re­
sult in starting and driveability problems. In addition,
damage may be done to critical fuel system compo­
nents.

Methanol (Methyl or Wood Alcohol) is used in a va­
riety of concentrations blended with unleaded gaso­
line.
You may encounter fuels containing 3 percent
or more methanol along with other alcohols called co-
solvents.
Problems that are the result of using methanol/gas­
oline blends are not the responsibility of Chrysler Corporation. They may not be covered by the vehicle
warranty.

MTBE/ETBE
Gasoline and MTBE (Methyl Tertiary Butyl Ether)
blends are a mixture of unleaded gasoline and up to 15 percent
MTBE.
Gasoline and
ETBE
(Ethyl
Ter­

tiary Butyl Ether) are blends of gasoline and up to 17 percent ETBE. Gasoline blended with MTBE or
ETBE may be used in your vehicle.

CLEAN
AIR GASOLINE Many gasolines are now being blended that con­
tribute to cleaner air, especially in those areas of the
country where air pollution levels are high. These
new blends provide a cleaner burning fuel and some are referred to as Reformulated Gasoline.
In areas of the country where carbon monoxide lev­
els are high, gasolines are being treated with oxy­
genated materials such as MTBE, ETBE and ethanol.
Chrysler Corporation supports these efforts toward
cleaner air and recommends that you use these gas­
olines as they become available.

FUEL
REQUIREMENTS-DIESEL ENGINE
Use good quality diesel fuel from a reputable sup­
plier in your Chrysler Corporation vehicle. For most
year-round service, number 2 (two) diesel fuel meet­ ing ASTM specification D-975 will provide good per­
formance. If the vehicle is exposed to extreme cold (below -18°C - 0°F), or for any reason is required to
operate at colder than normal conditions for pro­ longed periods, then dilution of the 2D fuel with 50
percent kerosine or number ID diesel fuel will pro­
vide better protection from fuel gelling or wax-plug­ ging of the fuel filters. Diesel fuel is seldom
completely free of water. To prevent fuel system
trouble, including fuel tube (line) freezing in winter, drain the accumulated water using the drain pro­
vided. If you buy good quality fuel and follow the cold weather advice above, fuel conditioners should
not be required in your vehicle.

•

FUEL SYSTEM
14 • 3
FUEL
DELIVERY SYSTEM-EXCEPT DIESEL

INDEX
page
Fuel Filter—3.9L/5.2L Gas Engine
............
10

Fuel
Filter—5.9L
Gas Engine
11
Fuel Pressure Leak Down Test—3.9L/5.2L Engine
. 8

Fuel Pressure Leak Down Test—5.9L Engine
.... 9

Fuel Pump Capacity
Test—All
Gas
Engines
..... 8

Fuel Pump
Control
........................
5

Fuel Pump Module—3.9L/5.2L Engines
3

GENERAL INFORMATION
Two different types
of
fuel delivery/fuel return sys­
tems
are
used.
The
system used with
the
3.9L/5.2L
engine will route excess fuel pressure back
to the

fuel tank through
a
fuel return line.
The
system used
with
the 5.9L
engine will
not
have
a
separate fuel
re­

turn line. This system will
be
referred
to as a re-

turnless type.
The
fuel pump module used with
the
5.9L engine will contain
a
combination fuel pressure
regulator
and
fuel filter. Refer
to the
following Fuel
Pump Module
for
additional information
or,
refer
to

the Multi-Port Fuel Injection sections
of
this Fuel System group. A separate frame mounted fuel filter will
not be

used with
any 5.9L gas
powered engine.

FUEL
PUMP
M0DULE-3.9L/5.2L
ENGINES
The fuel pump module
on
vehicles equipped with
3.9L/5.2L engines
is
installed
in the top of the
fuel
tank (Fig.
1). The
fuel pump module contains
the
fol­ lowing components (Fig.
2):

• Fuel pump
• Fuel pump reservoir
•
A
separate in-tank fuel filter
• Pressure relief/rollover valve
PRESSURE
RELIEF/
PUMP/GAUGE

Fig.
1
Top View
of
Fuel
Pump
Module—3.9U5.2L
Engine
page
Fuel Pump Module—5.9L Engine
.............
3

Fuel System Pressure Release
...............
5

Fuel System Pressure Test—3.9L/5.2L Engine
... 5
Fuel System Pressure Test—5.9L Engine
7

Fuel Tubes/Lines/Hoses
and
Clamps
..........
11

General
Information
3

Quick-Connect
Fittings
11

• Fuel pump gauge sending unit
• Fuel supply
and
return tube connections
J9114-147

Fig.
2
Fuel
Pump
Module
Components—Typical

FUEL PUMP MODULE—5.9L ENGINE
The fuel pump module
on
vehicles equipped with
a

5.9L
gas
powered engine
is
installed
in the top of
the
fuel tank
(Fig. 3). The
fuel pump module contains
the following components (Fig.
2):
• Fuel filter/fuel pressure regulator
• Fuel pump • Fuel pump reservoir
•
A
separate in-tank fuel filter
• Pressure relief/rollover valve
• Fuel pump gauge sending unit
• Fuel supply tube connection

FUEL
TUBE

REMOVAL

QUICK
CONNECT

FITTING

PUSH
PUSH PUSH

INSTALLATION

X
PUSH

/

•PUSH

PLASTIC

RETAINER
J9314-100

Fig. 19 Removing/Installing Quick-Connect Fitting (8) If pressure falls below 24 psi, it must deter­
mined if a fuel injector, the fuel module mounted fuel
pressure regulator or a fuel tube/line is leaking. (9) Again, start engine and bring to normal oper­
ating temperature.
(10) Shut engine off.
(11) Checking for fuel injector leakage: Clamp
off the rubber hose portion of tool 6539 between the
disconnected fuel tube (line) and test port inlet. If
pressure now holds at or above 24 psi, a fuel injector or the fuel rail is leaking.
Checking for fuel pressure regulator or fuel
tube leakage: Clamp off the rubber hose portion of
tool 6539 between the fuel rail and test port inlet. If
pressure now holds at or above 24 psi, a leak can be
found at a fuel tube/line. If no leaks are found at fuel

tubes,
replace the fuel filter/fuel pressure regulator.

MECHANICAL MALFUNCTIONS
Mechanical malfunctions are more difficult to diag­
nose with this system. The powertrain control mod­
ule (PCM) has been programmed to compensate for
some mechanical malfunctions such as incorrect cam
timing, vacuum leaks, etc. If engine performance
problems are encountered and a diagnostic trouble code (DTC) is not displayed, the problem may be me­
chanical rather than electronic.

FUEL FILTER-3.9L/5.2L GAS ENGINE
For diesel engines, refer to Fuel/Water Separator
Filter in the Diesel Fuel Injection—Service Proce­
dures section of this group.
REMOVAL

WARNING:
THE
FUEL
SYSTEM
IS
UNDER
A
CON­
STANT
PRESSURE
(EVEN
WITH
THE
ENGINE
OFF).
BEFORE
SERVICING
THE
FUEL FILTER,
THE
FUEL
SYSTEM
PRESSURE
MUST
BE
RELEASED.

The fuel filter is located under the vehicle and near
the fuel tank. It is mounted to the frame rail (Fig.
20). (1) Perform Fuel System Pressure Release proce­

dure.
(2) Disconnect negative battery cable from battery.
(3) Raise and support vehicle.
(4) Remove and discard both fuel hose-to-fuel filter
hose clamps. (5) Wrap a shop towel around hoses to absorb fuel.
Remove hoses at filter. (6) Remove filter from frame.
FUEL
HOSES
HOSE
CLAMPS
.
FILTER
MOUNTING
BOLT
FUEL

FILTER

J9214-68

Fig.
20
Fuel
Filter—3.9U5.2L
Engine

INSTALLATION

CAUTION:
The
tubes/hoses used
on
fuel
injected

vehicles
are of a
special construction. This
is due

to
the
higher
fuel
pressures
and the
possibility
of
contaminated
fuel
in
this system.
If it is
necessary
to replace these tubes/hoses, only tubes/hoses marked EFM/EFI
may be
used.

CAUTION:
The
hose clamps used
on
fuel
injected

vehicles
are of a
special rolled edge construction
to
prevent
the
edge
of the
clamp from cutting into
the
hose.
Only these rolled edge
type
clamps
may be

used
in
this system.
All
other types
of
clamps
may

cut into
the
hoses
and
cause high pressure
fuel
leaks.

(1) Install fuel filter to frame rail. Tighten mount­
ing bolt to 8 N»m (75 in. lbs.) torque. (2) Install new original equipment clamps to fuel

hoses.